Posted February 13, 2025

Introduction to KALLER products

The purpose of this blog post is to provide a introductory overview of KALLER products to learn more of the broad variety, the different benefits and features, and various solutions we offer. 

Contents:

  1. Why Choose Gas Springs?
  2. Why Choose KALLER?
  3. What Kind of Products does KALLER Provide?
  4. Standard Gas Springs
  5. Problem Solvers & Cost-Reduction Solutions
  6. Safety & Reliability - Reduce Your Risks
  7. Remote Pressure Monitoring Systems
  8. Mounts, Accessories, & More
  9. Gas Spring Selection Guide

 

Why Choose Gas Springs?

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Compared to coil springs or hydraulics, nitrogen gas springs provide impressive force in a compact space. They do not leak contaminating hyraulic or other fluids that can damage produced parts or the surrounding workspace. 

Compared to Coil Springs

  • Longer lasting
  • Safer
  • No pre-load
  • High initial force
  • Higher force in smaller form
  • Can adjust force
  • Easier maintenance
  • Reduce risk of tool damage

Compared to Hydraulics

  • More environmentally friendly (hydraulic fluid can also damage the tool or end parts if leaked)
  • Smaller form factor
  • Saves electricity costs
  

 

Why Choose KALLER?

  • Trusted Worldwide: KALLER products are consistently trusted by major OEMs because they are designed and manufactured to have the best Quality, Safety, and Reliability in the market. 
  • Save with KALLER: With reliable quality and cost-reduction solutions you can ensure a smooth operation with less downtime, less scrap parts, and better part quality.
  • Service & Support: For over 40 years we have provided unparrallel support for application solutions, practical and online training, calculators & tools, and a variety of other services to ensure you are provided the help you need.
  • Available Globally & Locally: Through our vast global network that both supplies and provides support, you kind find KALLER around the world from your local service point or distributor.
  • The Leader in Safety: Reduce risks and liabilities with KALLER's advanced Safety Features and design. 

 

What Kind of Products does KALLER Provide?

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Gas Hydraulic Suspension

Counterbalance & Industrial Cylinders

Tool & Die

Military-grade suspension systems for heavy-duty and off-road vehicles.

  • Tracked tanks
  • Wheeled vehicles (4x4, 6x6, 8x8)

A wide variety of industrial applications where compact force or counterbalance is required.

  • Automation
  • Agriculture
  • Actuators
  • Drill Rigs
  • Machine Industry

A large variety components to optimize die operations.

  • Standard Gas Springs
  • Delayed Return Units
  • Piercing, Forming, and Roller Cam Units
  • Lifters
  • Basepalts
  • Manifold Systems
  • Remote Pressure Monitoring System
  • Accessories

Standard Gas Springs

PEDapproval2millionStroke_new.jpg With a very large selection, many of our standard springs are found on major OEM and company standards around the world because of the top-tier Quality, Safety, and Reliability. KALLER Gas springs are designed, manufactured, and tested for top quality and are approved according to PED 2014/68/EU.

 

 

See our Gas Spring Selection Guide below.

 

 

Calculate According to Your Operation

Find the right configuration with our Calculators and Configure according to various parameters.

Nitrogen Gas Spring Cylinder Force Calculator KALLER.PNG Flex Cam Configurator KALLER.PNG KF2 Controllable Gas Spring Calculator KALLER.PNG

Force & Temperature Calculator

Determine the force profile and operating temperature for Gas Springs.

Flex Cam Configurator

Simplifies the selection process for flex cam systems.

Controllable Gas Springs KF Calculator

Determine system and cooling performance for Controllable Gas Springs (KF).

 

Problem Solvers & Cost-Reduction Solutions

We offer a variety of solutions to fit your needs, see a list of a few below. Also, see our Cost Effective Guide for detailed guides on cost saving solutions.

  Product/ Series Benefits
Kaller-total-cost-reduction-reduce-tooling.png KF2 (Controllable Gas Springs/ Delayed Return Unit) Reduce the number of dies, improve part quality, & reduce downtimes. See the Case Study
KALLER Flex Cam for EV fender .png Flex Cams Reduce tooling costs, reduce maintenance, & able to be retrofitted. See the Case Study
LCF-series-collection.png
 LCF Series (Low Contact Force) Reduce shock load, reduce pad/ blank-holder bounce, noise reduction.
Speed Control Gas Spring.png SPC Series (Speed Control) Reduce blank holder bounce, increase strokes per minute, & increase productivity. See the Case Study
HDP_KALLER_gif.gif HDP (Protective Covers) Reduce maintenance times, prolong gas spring lifetime, & reduce downtimes. See Hot Stamping Example
Toolmind-Ecosystem-illustration.png Toolmind (Remote Pressure Monitoring) Monitor and stop production when pressure or temperature is outside set perameters.

 

 

Safety & Reliability - Reduce Your Risks

Reduce unnecessary safety risks and liabilities with KALLER quality as well as incorporated feature designs to keep you safe and production running reliabily. 

 

Safety Features:

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Overstroke Protection

Prevents the gas spring bursting in the event of an over stroke.

Overload Protection

Prevents the piston rod on the gas spring from ejecting.

Overpressure Protection

Prevents the gas spring bursting in the event of an over pressure.

 

 

Reliability Features:

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Flex Guide™ System

Prolongs service life, allows more strokes per minute, and offers greater tolerance to lateral tool movement.

Dual Seal™ Link System

Reduce production downtime due to leakages caused by vibrations with this advanced linked system technology.

 

 

Remote Pressure Monitoring System - Toolmind

Toolmind is a remote monitoring system that seamlessly integrates into new and existing production systems.

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Benefits:

  • Monitor force and temperature
  • Automatically stop production from set parameters
  • Quick change out times with simple monitoring
  • Save on scrapped parts

 

 

Mounts, Accessories, & More

Mounts

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KALLER provides a variety of Mounts for different orientations and applications such as Base Mount, Drop-in, Top and Foot Mount, Side Port, etc. 

TIP! Different KALLER Gas Springs are compatible with different mounting possibilities. Ensure the gas spring you choose is compatible with your desired mounting option- refer to the the gas spring product web page or in the KALLER Catalog for further details of compatibility.

 

Accessories

KALLER Accessories are to make your life easier with installation, adjustment, use, and maintenance of KALLER gas springs. 

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Gas Link Systems: A variety of Control Blocks and Hoses.

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Equipment and Tools: To assist during servicing and filling/ charging of nitrogen gas springs. 

 
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HDP (Heavy Duty Protection): Protective covers in contaminating environments to ensure smoother and more reliable production times with less maintenance.

 

More

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Manifold Systems: The SuperBrute® Nitrogen Manifold Systems by Forward provides seamless die transitions, constant force, adjustable pressure and simplified maintenance.
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Basplate Systems: As part of General Motors (GM) standard requirements, Base Plate systems are an alternative Gas Link systems without external or exposed hoses

 

Need Help Choosing? Right for the Application? | Contact Us!

With decades of experience in finding solutions to various applications, backed by a global network of experts, we are glad to assist you in finding the right gas spring for your needs. 

 

Contact us

Thank you for your interest in KALLER. Meeting your needs is our top priority. Please fill out this form completely, including a brief message about your request, and we will connect you with an expert who will be in touch with you as soon as possible.

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Gas Spring Selection Guide

Series
Description
Gas Spring Model
Stroke Lengths
 Initial Force at Max. Pressure
Total Length
Cylinder Diameter
      (mm) (N) (lbf) (mm) (mm)
EP3 16
 Color coded gas Ejector-Pins, interchangeable with mechanical spring plungers. EP3 16 10-125 420 95 45+(2xStroke) M16x1.5/M16x2
EPS3 16
 EPS3 16 10-125 420 95 45+(2xStroke) M16x1.5
EP2 24
 EP2 24 10-125 1,700 382 45+(2xStroke) M24x1.5
EPS2 24
 EPS2 24 10-125 1,700 382 45+(2xStroke) M24x1.5
R12
 Rod sealed and color coded gas springs – compact and fully adjustable. R12 7-125 500 112 56-295 Ø12
R15
 R15 7-125 700 160 56-295 Ø15
R19
 R19 7-125 900 202 56-295 Ø19
M2
 Repairable, color coded and fully adjustable gas springs available with or without threaded cylinders. M2 10-125 2,000 450 62-295 Ø25
MM2
 MM2 10-125 2,000 450 42+(2xStroke) M28x1.5
MC3
 MC3 10-125 2,000 450 50+(2xStroke) Ø32
MC3-SP
 MC3-SP 10-125 2,000 450 50+(2xStroke) Ø32
CU4
 Super compact gas springs providing extreme initial forces with minimal cylinder diameters. CU4 420 6-50 4,250 955 56-195 Ø25
CU4 740 6-50 7,400 1,660 63-195 Ø32
CU4 1000 6-50 10,600 2,400 61-230 Ø38
CU4 1800 6-65 18,000 4,050 66-271 Ø50
CU4 2900 10-65 29,500 6,630 85-256 Ø63
CU4 4700 10-65 47,000 10,570 80-273 Ø75
CU4 7500 10-65 75,000 16,860 90-279 Ø95
CU4 11800 10-65 118,000 26,530 100-320 Ø120
CU4 18300 10-65 183,000 41,140 110-323 Ø150
CX
 Compact Xtreme CX gas springs provide extreme forces by enabling high charge pressures. CX 500 10-80 5,100 1,150 75-145 Ø32
CX 1000 10-80 9,800 2,200 75-240 Ø38
CX 1900 10-80 19,200 4,320 80-245 Ø50
X
 The world’s shortest, strongest and most advanced rod sealed gas springs. X 170 7-125 1,700 382 44-285 Ø19
X 320 7-125 3,200 720 44-285 Ø25
X 350 10-125 3,600 810 30+(2xStroke) Ø32
X 500 10-125 4,700 1,055 30+(2xStroke) Ø38
X 750 10-125 7,400 1,665 32+(2xStroke) Ø45
X 1000 13-125 9,200 2,068 38+(2xStroke) Ø50
X 1500 13-125 15,000 3,375 44+(2xStroke) Ø63
X 2400 16-125 24,000 5,396 45+(2xStroke) Ø75
X 4200 16-125 42,000 9,440 58+(2xStroke) Ø95
X 6600 16-125 66,300 14,905 68+(2xStroke) Ø120
X 9500 19-125 95,000 21,400 78+(2xStroke) Ø150
X 20000 19-125 200,000 45,000 110+(2xStroke) Ø195
XG
 The Power Line XG series is based on the X series with the same features but additional total length providing a larger G 1/8" charge port and longer bottom threads. XG 350 10-125 3,600 810 40+(2xStroke) Ø32
XG 500 10-125 4,700 1,055 40+(2xStroke) Ø38
XG 750 10-125 7,400 1,665 47+(2xStroke) Ø45
XG 1000 13-125 9,200 2,068 52+(2xStroke) Ø50
XG 1500 13-125 15,000 3,375 52+(2xStroke) Ø63
XG 2400 16-125 24,000 5,396 59+(2xStroke) Ø75
XG 4200  16-125 42,000 9,440 62+(2xStroke) Ø95
XG 6600  16-125 66,300 14,905 72+(2xStroke) Ø120
XF
 The Power Line XF series is based on the X series with the same features but additional 10 mm total length providing a larger G 1/8” charge port. XF 750 10-125 7,400 1,665 42+(2xStroke) Ø45
XF 1000 13-125 9,200 2,068 48+(2xStroke) Ø50
XF 1500 13-125 15,000 3,375 54+(2xStroke) Ø63
XF 2400 16-125 24,000 5,396 55+(2xStroke) Ø75
TX
 The Power Line Heavy Duty series, a crossover between the standard TU series and the Power Line X series. Total length same as TU, force same as X. TX 750 13-200 7,400 1,665 85+(2xStroke) Ø45
TX 1000 13-300 9,200 2,068 95+(2xStroke) Ø50
TX 1500 13-300 15,000 3,375 95+(2xStroke) Ø63
TX 2400 25-300 24,000 5,396 110+(2xStroke) Ø75
TX 4200 25-300 42,000 9,440 120+(2xStroke) Ø95
TX 6600 25-300 66,300 14,905 140+(2xStroke) Ø120
TX 9500 25-300 95,000 21,400 155+(2xStroke) Ø150
TX 20000 25-300 200,000 45,000 160+(2xStroke) Ø195
TL
 The TL gas spring is shorter than the corresponding TU by 25 mm, except TL 5000 and TL 7500, which are 37.5 and 50 mm shorter respectively. TL 750 12.5-250 7,400 1,665 70+(2xStroke) Ø50
TL 1500 12.5-250 15,000 3,375 85+(2xStroke) Ø75
TL 3000 12.5-250 30,000 6,750 95+(2xStroke) Ø95
TL 5000 25-250 50,000 11,240 102.5+(2xStroke) Ø120
TL 7500 25-250 75,000 16,860 105+(2xStroke) Ø150
TU
 The TU gas springs' dimensions are the basis of the ISO 11901 standard for gas springs as well as the Ford WDX and GM gas spring standards. TU 250 10-125 2,650 600 50+(2xStroke) Ø38
TU 500 10-160 4,700 1,055 85+(2xStroke) Ø45
TU 750 12.7-300 7,400 1,665 95+(2xStroke) Ø50
TU 1500 25-300 15,000 3,375 110+(2xStroke) Ø75
TU 3000 25-300 30,000 6,750 120+(2xStroke) Ø95
TU 5000 25-300 50,000 11,240 140+(2xStroke) Ø120
TU 7500 25-300 75,000 16,860 155+(2xStroke) Ø150
TU 10000 25-300 106,000 23,830 160+(2xStroke) Ø195
TUS
 The High Speed gas springs (TUS) have been engineered to withstand press stroke speeds to a maximum of 2 m/s. TUS 750 25-300 7,4000 1,665 95+(2xStroke) Ø50
TUS 1500 25-300 15,000 3,375 110+(2xStroke) Ø75
TUS 3000 25-300 30,000 6,750 120+(2xStroke) Ø95
TUS 5000 25-300 50,000 11,240 140+(2xStroke) Ø120
TUS 7500 25-300 75,000 16,860 155+(2xStroke) Ø150
LCF
 These innovative Low Contact Force gas spring are 100% interchangeable with ISO gas springs (i.e. TU series) and reduce shock loads, noise levels and pad bounce problems. LCF 750 12.7-300 7,400 1,665 95+(2xStroke) Ø50
LCF 1500 25-300 15,000 3,375 110+(2xStroke) Ø75
LCF 3000 25-300 30,000 6,750 120+(2xStroke) Ø95
LCF 5000 25-300 50,000 11,240 140+(2xStroke) Ø120
LCF 7500 25-300 75,000 16,860 155+(2xStroke) Ø150
SPC
 Speed Control™ reduce or eliminate blank holder bounce; commonly associated with increased return stroke speeds from new generation of presses. SPC 750 80-300 7,400 1,665 110+(2xStroke) Ø75
SPC 1500 125-300 15,000 3,375 120+(2xStroke) Ø95
SPC 3000 125-300 30,000 6,750 140+(2xStroke) Ø120
SPC 5000 125-300 50,000 11,240 155+(2xStroke) Ø150
MT
 Mould Temp gas springs are compact and powerful piston rod sealed gas springs, which can be used up to 120°C. MT 16 10-80 420 95 48+(2xStroke) M16x1.5
MT 24 10-80 1,700 382 48+(2xStroke) M24x1.5
MT 300 10-80 3,000 675 30+(2xStroke) Ø32
MT 500 10-80 4,700 1,055 30+(2xStroke) Ø38
MT 750 10-80 7,440 1,665 32+(2xStroke) Ø45
MT 1000 13-80 9,200 2,068 38+(2xStroke) Ø50